Hockey Blade with Wrapped, Stitched Core

ABSTRACT

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

This application claims priority to and the benefit of and is acontinuation of U.S. Non-Provisional application Ser. No. 12/469,349,filed on May 20, 2009 which claims priority to and the benefit of and isa divisional application of U.S. Non-Provisional patent application Ser.No. 12/048,976 filed Mar. 14, 2008, now U.S. Pat. No. 7,824,591, all ofwhich are incorporated herein fully by reference.

FIELD OF THE INVENTION

This invention relates generally to fabrication of molded structures.More particularly, aspects of this invention relate to hockey bladesmolded from foam that is wrapped with a layer of tape, stitched, andwrapped with another layer of tape.

BACKGROUND

Typical hockey stick blades are generally made of a core reinforced withone or more layers of synthetic materials such as fiberglass, carbonfiber or Aramid. The core of the blade may also be made of a syntheticmaterial reinforced with layers of fibers. The layers may be made of awoven filament fiber, preimpregnated with resin. Prior art structureshave included a foam core with a layer of preimpregnated tape in themanner of pieces of bread on a sandwich, with a layer of tape on the topand bottom surfaces of the foam but not extending continuously along theedges of the core.

SUMMARY

The following presents a general summary of aspects of the invention inorder to provide a basic understanding of the invention and variousfeatures of it. This summary is not intended to limit the scope of theinvention in any way, but it simply provides a general overview andcontext for the more detailed description that follows.

Aspects of this invention relate to systems and methods for fabricatinga formed structure with a stitched foam core. A foam core is formed. Thefoam core includes a first core face, a second core face, a top coreedge and a bottom core edge. The foam core is wrapped with a first layerof fiber tape. The first layer of fiber tape extends continuously alongthe first core face, top core edge, second core face and bottom coreedge of the foam core. The wrapped core has a first wrapped face, asecond wrapped face, a top wrapped edge and a bottom wrapped edge.

The wrapped foam core is stitched with a thread. The thread extendsbetween and along the first wrapped face and the second wrapped face.

The stitched wrapped core is wrapped with a second layer of fiber tapeto form a wrapped preform. The second layer of fiber tape extendscontinuously atop the first layer of fiber tape and along the firstwrapped face, the top wrapped edge, the second wrapped face and thebottom wrapped edge.

The wrapped preform is placed in a mold. The mold is heated and cooled.The formed structure is removed from the mold.

In an embodiment of the invention, the formed structure may be a hockeyblade.

In an embodiment of the invention, the fiber tape is carbon fiber tapepreimpregnated with resin and the second layer of tape is substantiallythicker than the first layer.

In an embodiment of the invention, a single layer of fiber tape is usedto wrap the foam core with a first layer of fiber tape and a pluralityof layers of tape are used to wrap the stitched preform with a secondlayer of fiber tape.

The thread may be polyester or carbon fiber or carbon fiberpreimpregnated with resin.

Other objects and features of the invention will become apparent byreference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention and certainadvantages thereof may be acquired by referring to the followingdetailed description in consideration with the accompanying drawings, inwhich:

FIG. 1 generally illustrates a side view of foam formed in the shape ofa blade;

FIG. 2 is a perspective view of the blade of FIG. 1;

FIG. 3 is a perspective view of the blade of FIG. 2 after it is wrappedwith a layer of tape;

FIG. 4 is a perspective view of the blade of FIG. 3 after the blade isstitched;

FIG. 5 is a perspective view of the blade of FIG. 5 after it is wrappedwith additional layers of tape;

FIG. 6 is a perspective view of the blade of FIG. 2 with a crosssectional view taken along line 6-6;

FIG. 7 is a perspective view of the blade of FIG. 3 with a crosssectional view taken along line 7-7;

FIG. 8 is a perspective view of the blade of FIG. 4 with a crosssectional view taken along line 8-8;

FIG. 9 is a perspective view of the blade of FIG. 5 with a crosssectional view taken along line 9-9;

FIG. 10 is a flow diagram illustrating steps of a process to fabricate ablade in accordance with the invention.

FIG. 11 is a perspective view of the blade of FIG. 2 after it is wrappedwith a layer of tape in an alternative arrangement from that shown inFIG. 3;

FIG. 12 is a perspective view of the blade of FIG. 11 after it iswrapped with an additional layer of tape prior to stitching;

FIG. 13 is a side view of the blade of FIG. 11 wrapped with a layer oftape;

FIG. 14 is a side view of the blade of FIG. 13 wrapped with anotherlayer of tape prior to stitching; and

FIG. 15 is an illustration of a stitched, wrapped preform with analternative stitching pattern.

The reader is advised that the attached drawings are not necessarilydrawn to scale.

DETAILED DESCRIPTION

In the following description of various example structures in accordancewith the invention, reference is made to the accompanying drawings,which form a part hereof, and in which are shown by way of illustrationvarious structures in accordance with the invention. Additionally, it isto be understood that other specific arrangements of parts andstructures may be utilized, and structural and functional modificationsmay be made without departing from the scope of the present invention.Also, while the terms “top” and “bottom” and the like may be used inthis specification to describe various example features and elements ofthe invention, these terms are used herein as a matter of convenience,e.g., based on the example orientations shown in the figures and/or theorientations in typical use. Nothing in this specification should beconstrued as requiring a specific three dimensional or spatialorientation of structures in order to fall within the scope of thisinvention.

In general, as described above, aspects of this invention relate tosystems and methods for fabricating a structure, such as a hockey stickblade. More detailed descriptions of aspects of this invention follow.

FIG. 1 illustrates a foam core 30. The foam may be a polymethacrylimide(PMI) foam such as manufactured under the name Rohacell. A suitable lowdensity PMI foam is RIMA (Resin Infusion Manufacturing Aid) foam. Thistype of foam is a high strength foam that can withstand the shear andimpact forces that result when a hockey blade strikes a hockey puck.

FIG. 2 is a perspective view of the foam core 30 of FIG. 1. Analternative view of the foam core 30 is shown in FIG. 6, which isperspective view of the foam core 30 of FIG. 2 along lines 6-6. The foamcore 30 includes a first core face 32, a second core face 34, a top coreedge 36 and a bottom core edge 38.

In FIG. 1 and FIG. 2, an outline of a handle portion of the structure isshown in dashed lines to illustrate how the foam core 30, onceultimately formed into a blade as described in this specification, isconfigured as part of a hockey stick that includes a blade and a handle.

Referring to FIG. 3 and FIG. 7, the foam core 30 is wrapped with a layerof carbon tape 40 that is preimpregnated with resin, resulting in awrapped structure 60. The tape 40 is wrapped continuously around thefirst core face 32, the second core face 34, the top core edge 36 andthe bottom core edge 38 of the foam core 30. This continuous wrapping ofthe foam core 30 with the tape 40 results in a first wrapped face 52, asecond wrapped face 54, a top wrapped edge 56 and a bottom wrapped edge58.

In one embodiment, the foam core 30 is wrapped with a single layer ofcarbon tape 40. Wrapping the foam core 30 with too many layers of carbontape prior to stitching results in wrinkling of the tape when it isstitched, as discussed later in the specification. In FIG. 7, thethickness of the layer of tape 40 is exaggerated so that it can be moreclearly illustrated.

In one embodiment, a veil or scrim material (not shown) in the form of athin non-tacky layer of woven fiberglass or polyester is then placedalong the first wrapped face 52. Another piece of such material isplaced along the second wrapped face 54. The veil is placed on thewrapped faces 52, 54 in the manner of a sandwich, with a single layer ofmaterial on each face. The veil does not extend continuously around thewrapped edges 56, 58.

As shown in FIG. 4 and FIG. 8, the wrapped core 40 is then stitched witha thread 70 to create a wrapped, stitched core 72. The thread 70 may bea high strength polyester thread that can withstand heating and maintainits physical properties at and above the temperature of the mold, 140degrees C. The thread may also be a carbon fiber thread or a carbonfiber thread preimpregnated with resin.

The stitching is accomplished with an industrial sewing machine (notshown). Placement of structure wrapped with tape preimpregnated withresin in a sewing machine can cause the machine to stick or jam, and itcan otherwise be difficult to operate the sewing machine with and on asticky structure. The veil material described above is not sticky andthus makes it easier to stitch the wrapped core in the sewing machine.

As shown in FIG. 8, the thread extends from the first wrapped face 52through the core 30 to the second wrapped face 54. The thread createsthe effect of an I-beam between the first wrapped face 52 and the secondwrapped face 54 and adds structural and shear strength and rigiditybetween the faces. If the veil (not shown in FIG. 8) were used, it wouldbe positioned along the wrapped faces 52, 54, and the stitching 70 wouldbe positioned along the veil.

As shown in FIG. 8, the thread 70 also pulls the tape 40 toward thefirst wrapped face 52 and the second wrapped face 54 and the point wherethe thread 70 enters the core 30. As is further illustrated in FIG. 8,the wrapped, stitched core 72 is not flat in that the result of thethread 70 pulling the tape 40 toward the core 30 and various locationscreates a somewhat bumpy or pillow effect on the surface of the firstwrapped face 52 and the second wrapped face 54. As with FIG. 7, thethickness of the tape 40 is exaggerated in FIG. 8 for purposes of moreclearly illustrating the invention.

In one embodiment of the invention, the thread is stitched onto the tape40 in a series of three parallel lines of stitching, as shown in FIG. 4and FIG. 8. In an alternative embodiment of the invention (not shown),eight parallel lines of thread are used. In another embodiment, there isno set or predetermined pattern to the thread.

The wrapped stitched core 72 is then wrapped with at least oneadditional, second layer of tape 82 to form a wrapped preform 80. Thewrapped stitched core 72 may be wrapped with multiple layers of tape 82as shown in FIG. 9. The tape 82 is made of the same material as the tape40. The second layer of tape 82 extends continuously atop the firstlayer of fiber tape 40 and along the first wrapped face 52, the topwrapped edge 56, the second wrapped face 54 and the bottom wrapped edge58. In an embodiment of the invention, 80-90% of the overall thicknessof the tape is in the second layer and 10-20% of the thickness of thetape is in the first layer.

The wrapped blade includes 8-10 total layers of tape. One to threelayers of tape are applied to the foam core prior to stitching, and fiveto nine layers of tape are applied after stitching and before insertioninto the mold. For example, when eight total layers are used, differentembodiments include different combinations of layers of tape before andafter stitching, including one and seven; two and six; and three andfive.

After stitching and the additional layer of tape are applied, theresulting faces are first face 86 and second face 88. The result of theadditional layer or layers of tape 82 is that the face 86 and the face88 do not have a bumpy or pillow effect. Rather the faces 86 and 88 aresmooth and even, which is preferable for insertion into the mold andformation of a hockey blade.

As shown in FIG. 3-5, the foam core includes a toe 45. The tape 40 andthe tape 82 extends around the entire core, to the end of the toe 45,but for purposes of more clearly illustrating the invention in thefigures, the tape 40 and tape 82 is not shown in FIG. 3-5 extending tothe end of the toe 45 of the core.

The wrapped preform 80 is then placed in a mold. The mold is heated toan appropriate temperature. In one embodiment, the mold is heated to 140degrees C. When the mold is heated, the foam 30 and tape 40 bond. Theresin in the preimpregnated tape 40 and 82 melts, flows through thewoven veil and bonds the materials together. Additionally, the resin inthe preimpregnated tape 40 and 80 flows along the stitches 70 into thecore 30. When this resin cools, it creates additional strength in thez-axis of the structure. Carbon fiber thread, which may be used in oneembodiment, shrinks when it is heated. Carbon fiber thread results in amore homogenous structure because the carbon fiber thread sharesproperties with the carbon fiber tape.

The mold is then cooled and the formed structure is removed from themold. The thread creates a stiffening agent that gives additionalresistance against shearing.

Stitching multiple layers of tape is undesirable for several reasons.Stitching multiple layers is more difficult because it is more difficultto drive the thread through many layers of tape. The resulting structureis also more unwieldy and is not flat and smooth. The pinching that isillustrated in FIG. 8 is further amplified when multiple layers arestitched, resulting in microkinks and other deformations that areundesirable in a hockey blade. For the same reasons, it is desirablethat the outer layer of the preform, the layer that contacts the mold,not be stitched.

Stitching the first layer creates the additional desirable effect thatthe preform is more stable during handling prior to insertion in themold. The carbon fiber tape on the preform also is less likely toballoon outward when heated in the mold because the stitching holds thecarbon fiber tape 40 against the core 30.

The use of continuous layers of tape wrapped around the entire core isadvantageous over a sandwich configuration for several reasons. Thehockey blade must be very durable and capable of withstanding largeforces from a variety of directions. For example, the hockey blade canencounter considerable forces, such as from a puck or the surface of theice in multiple manners and angles. Thus, the foam core needsreinforcement in all directions. The wrap configuration results in atorsionally stiffer and stronger structure. The wrap configuration alsois better able to withstand shear forces.

It is to be understood that a layer of tape or material need not consistof a single unitary piece or sheet of material. For example, a layer canconsist of a combination of multiple pieces or sheets that overlap.

The steps of the process are illustrated in FIG. 10. A foam core isformed as shown at 102. The foam core is wrapped with a first layer orlayers of fiber tape as shown at 104. The first layer of fiber tapeextends continuously along the first core face, top core edge, secondcore face and bottom core edge of the foam core, wherein the wrappedcore has a first wrapped face, a second wrapped face, a top wrapped edgeand a bottom wrapped edge. In one embodiment, a non-sticky veil isapplied to the first wrapped face and second wrapped face. The wrappedfoam core is stitched with a thread as shown at 106. The thread extendsbetween and along the first wrapped face and the second wrapped face.The stitched wrapped core is wrapped with a second layer or layers offiber tape to form a wrapped preform, as shown at 108. The second layerof fiber tape extends continuously atop the first layer of fiber tapeand along the first wrapped face, the top wrapped edge, the secondwrapped face and the bottom wrapped edge. The wrapped preform is placedin a mold, as shown at 110, and the mold is heated, as shown at 112. Themold is then cooled, as shown at 114, and the formed structure isremoved from the mold, as shown at 116.

FIGS. 11 and 12 shown an embodiment with alternative wrapping ofpreimpregnated carbon fiber tape 200 wrapped around the core prior tostitching. The core includes a toe 202. The tape 200 is wrapped at a 30or 45 degree angle to the longitudinal axis of the blade. A second layerof preimpregnated tape 204 is wrapped at a 90 degree angle to the tape200. The tape 200 and 204 extends to the end of the foam core to the toe202 (not shown in FIGS. 11 and 12). The tape 200 and 204 extendscontinuously around the faces and edges of the core.

FIGS. 13 and 14 further illustrate the wrapping configuration of FIGS.11 and 12. FIG. 13 shows a foam core of wrapped with a layer ofpreimpregnated tape 400. FIG. 14 shows the foam core wrapped with asecond layer of preimpregnated tape 402. After wrapping the core withtape in this configuration, a veil may be added to the wrapped core, andwrapped core is stitched, as described previously.

Referring to FIG. 5, the final layer or layers of tape that are wrappedon top of the stitched configuration prior to insertion in the mold canbe applied at a variety of angles, such as the angles shown in FIGS.11-14.

The stippling or dots in FIGS. 1-9 and 11-12 are to illustrate randomair bubbles in the foam. The stippling or dots are not drawn to scale.

FIG. 15 illustrates a stitched, wrapped preform with a layer of tape500, a second layer of tape 502 on the surface of the tape 500 andthread 504. The thread 504 is stitched in a criss-cross or diamondpattern. After stitching, an additional layer or layers of tape arewrapped around the preform before the preform is inserted into a mold.

The reader should understand that these specific examples are set forthmerely to illustrate examples of the invention, and they should not beconstrued as limiting the invention. Many variations in the connectionsystem may be made from the specific structures described above withoutdeparting from this invention.

While the invention has been described in detail in terms of specificexamples including presently preferred modes of carrying out theinvention, those skilled in the art will appreciate that there arenumerous variations and permutations of the above described systems andmethods. Thus, the spirit and scope of the invention should be construedbroadly as set forth in the appended claims.

1. A method for forming a construct for a hockey blade comprising:providing a foam core having a first face and a second face; adhering afirst layer of tape on the first face and the second face of the foamcore; applying a non adhesive scrim on the first layer of tape on thefirst face; and stitching a thread along the first layer of tape and thenon adhesive scrim on the first face of the foam core.
 2. The method asin claim 1 further comprising providing a second layer of tape on thefirst layer of tape.
 3. The method as in claim 2 wherein the secondlayer of tape is thicker than the first layer of tape.
 4. The method asin claim 1 wherein the non adhesive scrim is formed from of one of wovenfiberglass and polyester.
 5. The method as in claim 1 wherein the threadis one of high strength polyester, carbon fiber, and carbon fiberpreimpregnated with resin.
 6. The method as in claim 1 wherein thethread extends through the foam core to add structural and shearstrength and rigidity between the first face and the second face of thecore.
 7. The method as in claim 1 wherein the construct is stitchedalong the core in a series of at least three parallel lines ofstitching, in a criss-cross pattern or diamond pattern.
 8. The method asin claim 2 further comprising bonding the foam core and the layers oftape.
 9. The method as in claim 1 wherein the thread creates a pilloweffect on the first layer of tape when the thread is stitched along thefirst face of the foam core.
 10. A method comprising: forming a foamcore having a first core face, a second core face, a top core edge, anda bottom core edge; wrapping a first layer of fiber tape around thefirst core face, the second core face, the top core edge, and the bottomcore edge to form a wrapped foam core comprising a first wrapped coreface, a second wrapped core face, a wrapped top core edge, and a wrappedbottom core edge; placing a non-tacky veil on the first wrapped coreface and the second wrapped core face of the foam core; stitching thewrapped foam core with a thread, the thread extending between and alongthe first core face and the second core face; placing the wrapped foamcore in a mold; heating the mold such that the thread becomes embeddedin the foam core; cooling the mold; and removing the formed structurefrom the mold.
 11. The method of claim 10 further comprising wrapping asecond layer of fiber around the first layer of fiber tape.
 12. Themethod according to claim 10 wherein the formed structure is a hockeyblade.
 13. The method according to claim 10 wherein the fiber tape iscarbon fiber tape preimpregnated with resin.
 14. The method according toclaim 11 wherein the second layer of tape is substantially thicker thanthe first layer.
 15. The method according to claim 10 wherein a singlelayer of fiber tape is used in the step of wrapping the first layer offiber tape around the first core face, the second core face, the topcore edge, and the bottom core edge.
 16. A method comprising: forming afoam core, the core comprising a first core face, a second core face, atop core edge, and a bottom core edge; wrapping fiber tape around thefirst core face, the second core face, the top core edge, and the bottomcore edge to form a wrapped foam core comprising a wrapped first coreface, a wrapped second core face, a wrapped top core edge, and a wrappedbottom core edge; placing a first piece of non adhesive scrim on thewrapped first core face and a second piece of non adhesive scrim on thewrapped second core face of the foam core to form a sandwich structure;stitching the foam core with a thread, the thread extending between andalong the first core face and the second core face; adhering a secondlayer of fiber tape to the wrapped first core face and the wrappedsecond core face to form a preform; placing the preform in a mold;heating the mold; cooling the mold; and removing the formed structurefrom the mold.
 17. The method according to claim 16 wherein the formedstructure is a hockey blade.
 18. The method according to claim 16wherein the fiber tape is carbon fiber tape preimpregnated with resin.19. The method according to claim 16 wherein the second layer of tape issubstantially thicker than the first layer.
 20. The method according toclaim 16 wherein a single layer of fiber tape is used in the step ofwrapping fiber tape around the first core face, the second core face,the top core edge, and the bottom core edge.